High-speed printing and high-flow hotend tip replacement

High-speed printing allows you to significantly reduce print times while maintaining optimal quality. The Omega I60 is designed to support high-speed printing thanks to its advanced motion system, firmware optimisation, and robust extrusion system.

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High-speed printing increases movement and extrusion speeds, enabling faster part production. It requires precise calibration, proper temperature settings, and compatible hotend tip configurations to ensure that print quality is not compromised. In this article, you will learn how to prepare your printer for high-speed printing.

When printing at high speeds, the limiting factor is not just how fast the printer can move, but how much molten material can be pushed through the hotend tip per second. This is known as the maximum volumetric flow rate.

Standard hotend tips have narrower internal channels and less optimised geometry. As print speed increases, the extruder must push filament faster to keep up. However, if the nozzle cannot melt and extrude the filament at that rate, problems arise:

• Under-extrusion

• Clogs or jams

• Print failures

Key reasons to use high-flow nozzles in high-speed printing:

1. Maintain print quality at high speeds.
   They ensure consistent extrusion even when printing at speeds above 250 mm/s, preventing under-extrusion and maintaining dimensional accuracy.

2. Maximise printer capabilities.
   High-speed printers like the BCN3D Omega I60 are mechanically capable of high speeds, but without sufficient nozzle flow, their potential is limited.

3. Reduce print times safely.
   By increasing the nozzle’s throughput, you can leverage aggressive speeds to reduce production time without needing excessively high temperatures that could degrade material properties.

4. Improve layer adhesion.
   Faster and more consistent deposition enhances thermal bonding between layers, resulting in stronger prints even at higher speeds.

Key Considerations for High-Speed Printing

What is Input Shaper?

Input Shaper is a motion control algorithm that reduces vibrations and ringing by adjusting acceleration profiles. It enables faster printing with cleaner surfaces by compensating for mechanical resonances in the printer.

What is the K-factor?

K-factor compensates for the pressure build-up and lag in the nozzle during acceleration and deceleration. This improves corner sharpness and maintains consistent extrusion throughout speed changes.

Material Compatibility

All high-speed printing tests were performed using PLA specifically formulated for high-speed applications. Before printing at these speeds, ensure that your chosen material can be extruded at the desired flow rates without compromising print quality.

High-Flow hotend tips replacements

To print at high speeds, it is mandatory to use High Flow (HF) hotend tips, which are specifically designed to handle the increased material flow required. Below is the compatibility table for different material types:

Material Type	Compatible Hotend tips
Proto	0.4 HF, 0.6 HF
Impact	0.4 HF only
Custom materials	0.4 HF only

Now, in the Change Hotend Tip menu, you will see new options for high-speed hotend tips.

 

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Stratos profiles

In Stratos, you will find pre-optimised profiles for high-speed printing, following the compatibility table shown above.

Make sure to select the correct configuration between the hotend tip and the material to be able to use the profile.